VISVESVARAYA TECHNOLOGICAL UNIVERSITY
“Jnana Sangama”, Belagavi-590018
Project Report Phase-II (18MEP83)
on
“MODELING AND NUMERICAL ANALYSIS OF TOGGLE
MECHANISM FOR SIDE IMPACT TESTING MACHINE”
Submitted in the partial fulfillment of the requirement for the award of
Bachelor of Engineering
in
Mechanical Engineering
Submitted By
KISHORE H 1GV21ME404
PRASANTH J 1GV21ME406
SANJAY P 1GV21ME408
SATHISH N 1GV21ME409
Under the Guidance of
Dr. MANJUNATHA BABU N S
ASSOCIATE PROFESSOR AND HOD
Department of Mechanical Engineering
Dr. T THIMMAIAH INSTITUTE OF TECHNOLOGY
(Formerly Golden Valley Institute of Technology)
Kolar Gold Field – 563 120
2023-24
VISVESVARAYA TECHNOLOGICAL UNIVERSITY
“Jnana Sangama”, Belagavi-590018
Project Report Phase- II (18MEP83)
on
“MODELING AND NUMERICAL ANALYSIS OF TOGGLE
MECHANISM FOR SIDE IMPACT TESTING MACHINE”
Submitted in the partial fulfillment of the requirement for the award of
Bachelor of Engineering
in
Mechanical Engineering
Submitted By
KISHORE H 1GV21ME404
PRASANTH J 1GV21ME406
SANJAY P 1GV21ME408
SATHISH N 1GV21ME409
Under the Guidance of
Dr. MANJUNATHA BABU N S
ASSOCIATE PROFESSOR AND HOD
Department of Mechanical Engineering
Dr. T THIMMAIAH INSTITUTE OF TECHNOLOGY
Kolar Gold Field – 563 120
2023-24
Dr. T THIMMAIAH INSTITUTE OF TECHNNOLOGY
Department of Mechanical Engineering
Kolar Gold Fields –563120
CERTIFICATE
Certified that the Project work entitled “MODELING AND NUMERICAL
ANALYSIS OF TOGGLE MECHANISM FOR SIDE IMPACT TESTING MACHINE” is a
Bonafide work carried out by KISHORE H – 1GV21ME404, PRASANTH J -
1GV21ME406, SANJAY P - 1GV21ME408 and SATHISH N – 1GV21ME409 in the
partial fulfillment for the award of Bachelor of Engineering in Mechanical
Engineering of the Visvesvaraya Technological University, Belagavi during the year
2023-24. It is certified that all corrections/suggestions indicated for internal
assessment have been incorporated in the report deposited in the departmental
library.
The Project report has been approved as it satisfies the academic requirement in
respect of Project Work Phase II (18MEP83) prescribed for the said Degree.
…………………………. …………………………. ………………………….
Signature of Guide Signature of HOD Signature of Principal
Dr.Manjunatha Babu N S Dr. Manjunatha Babu N S Dr. SyedAriff
Name of Examiners Signature with Date
01.
02.
DECLARATION
We hereby declare that the Project work entitled “MODELING AND NUMERICAL
ANALYSIS OF TOGGLE MECHANISM FOR SIDE IMPACT TESTING
MACHINE” submitted to Visvesvaraya Technological University, Belagavi
Engineering in Mechanical Engineering is a record of bonafide work carried out
by us during the year 2023-24 in the partial fulfillment for the award of Bachelor of
under the supervision of Dr. Manjunatha Babu N S, Associate Professor, Department
of Mechanical Engineering, Dr. T Thimmaiah Institute of Technology – KGF.
We further declare that the work reported in this Project report has not been submitted and
will not be submitted, either in part or in full, for the award of any other degree or diploma
in this institute or any other institute or university.
Place: KGF
Date:
Signature of the Candidate
…………………………….. ……………………………..
Kishore H Prasanth J
(1GV21ME404) (1GV21ME406)
…………………………….. ……………………………..
Sanjay P Sathish N
(1GV21ME408) (1GV21ME409)
ACKNOWLEDGEMENT
I am expressing my sincere gratitude to the following people and acknowledge them for
supporting me in completing the project successfully.
With warm hearts and immense pleasure, I first thank the almighty for his grace and
blessings, which drove me to the success and pray for the showers through our life.
I would like to express my deep gratitude to Dr. T THIMMAIAH INSTITUTE OF
TECHNOLOGY for providing excellent infrastructure for the successful completion of this
project.
I am very much thankful to Dr. SYED ARIFF, Principal – Dr. TTIT and Dr.
MANJUNATHA BABU N S, Head of the Department – Dr. TTIT for providing support
for all project related activities.
Our sincere thanks, by heart and soul to our guide Dr. MANJUNATHA BABU N S, Head
of the Department and Project coordinator Dr. MOHAN KUMAR K , Associate professor,
Department of Mechanical Engineering, Dr. TTIT whose timely support and suggestions
went a long way in the completion of Project work.
KISHORE H PRASANTH J
(1GV21ME404) (1GV21ME406)
SANJAY P SATHISH N
(1GV21ME408) (1GV21ME409)
ABSTRACT
The development of the impact testing machine is successfully presented. The impact testing
machine is necessary for ascertaining the strength of metallic components in withstanding
applied load. A comprehensive design analysis was carried out to ascertain the various
component sizes of the Impact strength testing machine in order to create a path for precise
construction. Majority of the materials used in this fabrication were obtained locally.
The constructed machine yielded a maximum velocity of 4.9m/s on execution of Charpy and
Izod impact test. Great stability was achieved as a result of thick base plate and column
support used during construction. A crushing force of 68.05KN and an impactor head energy
of about 35J was able to impart the requisite deformation on the metallic specimen needed for
the Charpy and Izod tests. Keywords: Impact strength, Design, Construction, Crushing force.
Toggle mechanism is the combination of solid, usually metallic links (bars), connected by pin
(hinge) joints that are so arranged that a small force applied at one point can create a much
larger force at another point. For example. A toggle mechanism at work in a rock-crushing
machine, the numbered links are pin-connected at A, B, C, D, and E. Rotation of link 1 about
the fixed pivot A causes the block to slide back and forth. The relation between the force in
link 2 acting at C and the force W exerted on the block at D, and thus on the rock, depends on
the angle symbolized by the Greek letter theta, θ; the smaller the angle, the greater is W in
terms of F. For θ equal to one degree, W is nearly 29 times F.
Toggle mechanisms are used to obtain large force amplification in such applications as sheet
metal punching and forming machines. The toggle mechanism has many applications
overcome a large resistance with the small driving force is necessary, for example, Clutches,
Rock crushers, Truck tailgates, Vacuum circuit breakers , pneumatic riveters , punching
machines, forging machines, injection modelling machines, etc.
This apparatus is designed to evaluate forces within a toggle mechanism. Load is applied to
the two pairs of links by a hanger suspended from their connecting pivot. One end of the links
is pivoted to a base, and the other end is able to move sideways on low friction ball bearing
wheels.
Keywords: Modelling / die clamping mechanism, mechanical error analysis
CONTENTS
Details
ACKNOWLEDGEMENT
ABSTRACT
Chapter 1 Introduction 1
Impact testing machine 1
Toggle mechanism 1
Main parts of the toggle mechanism 2
History 5
Application 6
Principal and constraint functions 7
Chapter 2 Literature review 8
Chapter 3 Objectives and methodology 11
Objectives of the project 11
Methodology of the project 12
Chapter 4 Design, modelling and FEA analysis 14
Design of the side impact testing machine 14
Modelling of the side impact testing machine 18
Material selection 24
FEA analysis 25
Chapter 5 Result, discussion, Conclusion and future 36
scope
Results 36
Discussion 38
Conclusion 39
Future scope 41
References
LIST OF FIGURES
Figure No Discription Page No
1.1 Toggle Mechanism 1
1.2 Link 2
1.3 Joint 3
1.4 Base 3
1.5 Spring 4
1.6 Cam 4
1.7 James Watt 5
1.8 Principal and constraint functions 7
3.1 Objectives 11
3.2 Flow chart 12
4.1 Python Programming after Run 17
4.2 Metallic Links 18
4.3 CAM 19
4.4 Spring 20
4.5 Guideways 21
4.6 Cylinder 21
4.7 Final model 22
4.8 Displacement 28
4.9 Deformed Shape 28
4.10 Y Component Stress 28
4.11 Y Component Stress 28
4.12 X Component Stress 29
4.13 X Component Displacement 29
4.14 Von Mises Stress 29
4.15 Displacement 30
4.16 Deformed Shape 30
4.17 Y Component Stress 30
4.18 Y Component Stress 30
4.19 X Component Stress 31
4.20 X Component Displacement 31
4.21 Von Mises Stress 31
4.22 Displacement 32
4.23 Deformed Shape 32
4.24 Y Component Stress 32
4.25 Y Component Stress 32
4.26 X Component Stress 33
4.27 X Component Displacement 33
4.28 Von Mises Stress 33
4.29 Displacement 34
4.30 Deformed Shape 34
4.31 Y Component Stress 34
4.32 Y Component Stress 34
4.33 X Component Stress 35
4.34 X Component Displacement 35
LIST OF TABLES
Table No Discription Page No
4.1 Material properties 24
5.1 Spring design 36
5.2 FEA Results 37
